Systems And Methods For Controlling Inducer Motor Speed

ABSTRACT

Disclosed are exemplary embodiments of systems and methods for controlling inducer motor speed. In an exemplary embodiment, a method includes changing stator voltage of an inducer motor (e.g., by changing a firing angle of a triac, using a transistor, a silicon controlled rectifier or semiconductor controlled rectifier (SCR), other switching device, etc.); determining actual inducer motor speed (e.g., by using a hall effect sensor or other speed sensor, etc.); and after determining the actual inducer motor speed, changing the motor stator voltage (e.g., by changing the firing angle of the triac, etc.) to a value at which the actual inducer motor speed is controllably regulated and/or maintained substantially at a set speed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of allowed U.S. patentapplication Ser. No. 17/481,859, which published on Mar. 31, 2022 asU.S. Patent Application Publication US2022/0103104 and issuing as U.S.Pat. No. 11,611,302 on Mar. 21, 2023. U.S. patent application Ser. No.17/481,859 claims the benefit of and priority to Indian PatentApplication No. 202021041848 filed Sep. 26, 2020. The entire disclosuresof the above applications are incorporated herein by reference.

FIELD

The present disclosure relates to systems and methods for controllinginducer motor speed.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Single phase induction motors are commonly used as furnace inducermotors. A furnace inducer motor may be used to drive a fan for movingair through a furnace and heating vent pipes. The inducer motor-drivenfan may also be used to remove harmful gases (e.g., carbon monoxide,nitrogen oxide, etc.) out through furnace vents.

The speed of a single induction phase motor may be controlled bychanging the frequency of the line voltage or changing the voltage, tothereby change rotational speed of the single phase induction motor.Conventionally, triacs, hall effect sensors, and variable frequencydrive (VFD) motor controllers have been used to control the speed ofsingle phase induction motors to a set or desired revolutions per minute(RPM).

A variable frequency drive (VFD) is a type of motor controller that maybe used to drive an electric motor by varying the frequency and voltagesupplied to the electric motor, such as a fan or pump motor in aheating, ventilation and air conditioning (HVAC) system. A triac (triodefor alternating current) is a three terminal electronic semiconductordevice that conducts electrical current in either direction whentriggered. A hall effect sensor is a device that may be used to measurethe magnitude of a magnetic field, e.g., for speed detection, proximitysensing, positioning, and current sensing.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and is notintended to limit the scope of the present disclosure.

FIG. 1 is a flow chart illustrating an exemplary method of controllinginducer motor speed according to an exemplary embodiment.

FIG. 2 is a line graph of actual inducer motor speed and set inducermotor speed in revolutions per minute (RPM) versus time in seconds,which results were obtained via the exemplary method shown in FIG. 1 .

FIG. 3 is a block diagram of a system including an inducer motor with ahall sensor assembly, wherein the inducer motor may be controllable at adesired RPM in accordance with the exemplary method (e.g., algorithm,etc.) shown in FIG. 1 according to an exemplary embodiment.

FIG. 4 is a graphical representation of an inducer motor with a hallsensor assembly and a control board including a triac drive circuit torun the inducer. The inducer motor may be controllable at a desired RPMin accordance with the exemplary method (e.g., algorithm, etc.) shown inFIG. 1 according to an exemplary embodiment.

FIG. 5 shows an inducer including an inducer motor, motor shaft,magnetic hall sensor assembly, inducer motor supply voltage terminals,rotor, stator, and induced draft fan. The inducer motor may becontrollable at a desired RPM in accordance with the exemplary method(e.g., algorithm, etc.) shown in FIG. 1 according to an exemplaryembodiment.

FIG. 6 is another graphical representation of the inducer motor with thehall sensor assembly shown in FIG. 4 .

FIG. 7 illustrates a hall sensor assembly coupled with an inducer motorshaft, which may be used in exemplary embodiments of the presentdisclosure.

FIG. 8 illustrates furnace internals of an exemplary furnace in whichmay be used an inducer motor with a hall sensor assembly wherein theinducer motor may be controllable at a desired RPM in accordance withthe exemplary method (e.g., algorithm, etc.) shown in FIG. 1 accordingto an exemplary embodiment.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

As noted in the background above, triacs and hall effect sensors havebeen used to control the speed of single phase induction motors to aset/desired RPM. But as recognized herein, conventional methods havedifficulty controlling the speed of a single phase induction motor to aset/desired RPM using a triac and hall effect sensor as the inductionmotor speed oscillates too much and does not stay constant. And thevarying and oscillating induction motor speed may cause more or less airflow and/or may cause pressure switch (PSW) opening.

Accordingly, disclosed herein are exemplary embodiments of systems andmethods that enable induction motor speed to be controlled moreprecisely to a set RPM substantially without any oscillations (e.g.,without any appreciable detrimental oscillations, entirely without anyoscillations, etc.). In exemplary embodiments, a switching device (e.g.,a triac, transistor, a silicon controlled rectifier or semiconductorcontrolled rectifier (SCR), other suitable device, etc.) is used tocontrol motor stator voltage so that speed of the motor is controllable.A speed sensor (e.g., a hall effect sensor, other device operable formeasuring speed of a motor, etc.) is used to check or measure the actualinducer motor speed when the inducer stator voltage is changed (e.g., byvarying the triac firing angle, etc.). After the actual inducer motorspeed is obtained via the speed sensor, the motor stator voltage may bechanged (e.g., by changing the triac firing angle, etc.) to the valuethat provides the desired inducer motor speed. Disclosed herein areexemplary methods (e.g., method 100 shown in FIG. 1 , etc.) that help tocontrollably regulate and/or maintain constant inducer motor speedsubstantially without speed oscillations, e.g., for a single phase motorbeing used as inducer, etc. As recognized herein, conventional methodsusing triacs and hall effect sensors have failed to regulate inducermotor speed at a desired/set level, which may result in significantdetrimental speed oscillations.

As also recognized herein, motor speed of shaded-pole induction motorsand permanent split capacitor (PSC) induction motors is proportional tovoltage. Higher voltage is higher speed, lower voltage is low speed forany given load. The triac is gated later to give a lower voltage andearlier for a higher voltage. An earlier gate signal would usually be asmaller firing angle and later a higher firing angle.

With reference now to the figures, FIG. 1 shows a flow chartillustrating an exemplary method 100 of controlling inducer motor speedaccording to an exemplary embodiment. Initially, the method 100 maystart with control in an idle state at 104 (Control Idle State) andrequire the inducer to be ON at 108 (Inducer ON required). At 112, themethod 100 includes determining whether or not the inducer is ON. If theinducer is OFF, the triac is not fired as indicated at 116 (TriacFire=NO), and the method 100 returns back to process 108. Although theexemplary method 100 includes using a triac to control the motor statorvoltage, other exemplary embodiments may include other switching devicesfor controlling motor stator voltage such as transistors, siliconcontrolled rectifiers or semiconductor controlled rectifiers (SCR), etc.

If it is determined that the inducer is ON at 112, the method 100proceeds to process 120 for a comparison of the inducer set or requiredspeed (RPM) to the inducer max speed (RPM)(inducer_required_speed<INDUCER_MAX_SPEED_RPM). At 124, the method 100includes determining whether the inducer required speed (RPM) is lessthan the inducer maximum speed (RPM).

If the inducer required speed (RPM) is the inducer maximum speed (RPM),the maximum motor speed may be obtained by running the motor with fullline voltage. This may be achieved by having the triac ON with zero orminimum firing angle as indicated at 128.

If it is determined at 124 that the inducer required speed is less thanthe inducer max speed, then the method 100 proceeds to process 132 forcontrollably regulating inducer motor speed. At process 132, the method100 includes periodically checking a timer to see if the time hasexpired. By way of example, the timer may be configured such that thetime is within a range from 16 milliseconds to 96 milliseconds.

If it is determined at 134 that the timer's time has not expired, thenthe method 100 includes waiting.

But if it is determined at 134 that the timer's time has expired, thenthe method 100 proceeds to process 136 at which a hall effect sensor isused to obtain actual inducer motor speed. Although the exemplary method100 includes using a hall effect sensor to obtain actual inducer motorspeed, other exemplary embodiments may include other speed sensors ordevices for measuring the speed of the motor.

At process 140, the method 100 includes determining whether or notactual inducer motor speed is greater than a sum of required inducerspeed plus delta speed 1 (inducer_speed>(required_speed+delta speed 1)).In this example method 100, delta speed 1 equals 20 RPM, delta speed 2equals 10 RPM, and delta speed 3 equals 200 RPM. Delta speed 2 is the+/−delta RPM to required speed within which inducer motor speed ismaintained. Alternatively, other suitable RPM values may be used fordelta speed 1, delta speed 2, and delta speed 3 in other exemplaryembodiments. For example, delta speed 1 may be set to an RPM valuewithin a range from 30 RPM to 60 RPM (e.g., 30 RPM, 40 RPM, 50 RPM, 60RPM, etc.), delta speed 2 may be set to an RPM value within a range from10 RPM to 30 RPM (e.g., 10 RPM, 20 RPM, 30 RPM etc.), and delta speed 3may be set to an RPM value within a range from 100 RPM to 400 RPM (e.g.,100 RPM, 200 RPM, 300 RPM, 400 RPM, etc.).

If it is determined at 144 that actual inducer motor speed is greaterthan the sum of the required inducer motor speed plus delta speed 1,then the method 100 includes increasing speed control immediately atprocess 146. To increase the speed control at 146, the method 100includes turning on the triac with the highest firing angle (broadly, ahigher firing angle) to thereby obtain the lowest inducer voltage toreduce inducer motor speed (triac_fire_angle=INDUCER_MIN_SPEED_ANGLE).

But if it is determined at 144 that actual inducer motor speed is notgreater than the sum of the required inducer motor speed plus deltaspeed 1, then the method 100 includes determining at 148 whether or notactual inducer motor speed is less than a difference of required inducermotor speed minus delta speed 3 (inducer_speed<(required_speed−deltaspeed 3). In this example method 100, delta speed 3 is 200 RPM.

If it is determined at 152 that actual inducer motor speed is less thanthe difference of required inducer motor speed minus delta speed 3, thenthe method 100 proceeds to process 156 to quickly increase the inducermotor speed that is too low. To increase the inducer motor speed at 156,the method 100 includes turning on the triac with the lowest firingangle (broadly, a lower firing angle) to thereby obtain the highestinducer voltage to increase inducer motor speed(triac_fire_angle=INDUCER_MAX_SPEED_ANGLE).

But if it is determined at 152 that actual inducer motor speed is notless than the difference of required inducer motor speed minus deltaspeed 3, then the method 100 proceeds to process 160 for closer or moreprecise inducer motor speed correction. At 160, the method 100 includesdetermining whether or not actual inducer motor speed is less than adifference of required inducer motor speed minus delta speed 2(inducer_speed<(required speed−delta speed 2). In this example method100, delta speed 2 is 10 RPM, and delta speed 2 refers to the +/−deltaRPM to required speed within which inducer motor speed is maintained.

If it is determined at 164 that actual inducer motor speed is less thanthe difference of required inducer motor speed minus delta speed 2, thenthe method 100 proceeds to process 168 for closer or more preciseinducer motor speed correction. At 168, the method includes calculatinga speed difference (e.g., less than 10 RPM, etc.) of required inducermotor speed minus actual inducer motor speed. A percentage value (e.g.,25%, etc.) of the speed difference is considered as a triac firing angleoffset (firing_angle_offset=required_speed−inducer_speed). At 172, themethod 100 includes reducing the triac firing angle by the offset tothereby to increase inducer motor speed(triac_fire_angle=triac_fire_angle−firing_angle_offset).

For example, the speed difference would be 20 RPM if the required speedis 2000 RPM and the actual speed is 1980 RPM. In this example, the speeddifference of 20 RPM exceeds the 10 RPM delta speed 2. And 25% of 20 RPMspeed difference is 5 RPM. This value of 5 is used as the firing anglechange or offset from the existing triac firing angle. As anotherexample, the speed difference would be 5 RPM if the required speed is2000 RPM and the actual speed is 1995 RPM. Because the speed differenceof 5 RPM is less than the 10 RPM delta speed 2, there is no change inthe existing firing angle. Thus, as the error increases, the firingangle changes accordingly.

But if it is determined at 164 that actual inducer motor speed is notless than the difference of required inducer motor speed minus deltaspeed 2, then the method 100 proceeds to process 176 for closer or moreprecise inducer motor speed correction. At 176, the method 100 includesdetermining whether or not actual inducer motor speed is greater than asum of required inducer motor speed plus delta speed 2(inducer_speed>(required_speed+delta speed 2). In this example method100, delta speed 2 is 10 RPM, and delta speed 2 is the +/−delta RPM torequired speed within which inducer motor speed is maintained.

If it is determined at 180 that actual inducer motor speed is notgreater than the sum of required inducer motor speed plus delta speed 2,then no change is required. Accordingly, the triac firing angle is notchanged.

But if it is determined at 180 that actual inducer motor speed isgreater than the sum of required inducer motor speed plus delta speed 2,then the method 100 proceeds to process 184 for closer or more preciseinducer motor speed correction. At 184, the method includes calculatinga speed difference (e.g., 10 RPM, etc.) actual inducer motor speed minusrequired inducer motor speed. The percentage value (e.g., 25%, etc.) ofthe speed difference is considered as a triac firing angle offset(firing_angle_offset=inducer_speed−required_speed). At 188, the method100 includes increasing the triac firing angle by the offset to decreaseinducer motor speed(triac_fire_angle=triac_fire_angle+firing_angle_offset).

For example, the speed difference would be 25 RPM if the required speedis 2000 RPM and the actual speed is 2025 RPM. In this example, the speeddifference of 25 RPM exceeds the 10 RPM delta speed 2. And 25% of 25 RPMspeed difference is 6.25 RPM. This value of 6.25 is used as the firingangle change or offset from the existing triac firing angle. As anotherexample, the speed difference would be 5 RPM if the required speed is2000 RPM and the actual speed is 2005 RPM. Because the speed differenceof 5 RPM is less than the 10 RPM delta speed 2, there is no change inthe existing firing angle. Thus, as the error increases, the firingangle changes accordingly.

Also shown in FIG. 1 , the method 100 also includes load periodic checktimer at 192 (e.g., with a few milliseconds, etc.). The method 100further includes turn on triac with triac_fire_angle at 196 beforereturning back to process 108.

Disclosed are exemplary embodiments of systems and methods forcontrolling inducer motor speed. In exemplary embodiments, a methodincludes changing stator voltage of an inducer motor (e.g., by changinga firing angle of a triac, using a transistor, a silicon controlledrectifier or semiconductor controlled rectifier (SCR), other switchingdevice, etc.); determining actual inducer motor speed (e.g. using a halleffect sensor or other speed sensor, etc.); and after determining theactual inducer motor, changing the motor stator voltage (e.g., bychanging the firing angle of the triac, etc.) to a value at which theactual inducer motor speed is controllably regulated and/or maintainedsubstantially at a set speed.

For example, an exemplary method may include changing stator voltage ofan inducer motor by changing a firing angle of a triac; determiningactual inducer motor speed by using a hall effect sensor; and afterdetermining the actual inducer motor speed via the hall effect sensor,changing the firing angle of the triac to a triac firing angle value atwhich the actual inducer motor speed is controllably regulated and/ormaintained substantially at a set speed.

After determining the actual inducer motor speed, the method may includechanging the stator voltage of the inducer motor such that the actualinducer motor speed is controllably regulated and/or maintainedsubstantially at the set speed within less than 4 seconds and/orsubstantially without any speed oscillations and/or such that the actualinducer motor speed is controllably regulated and/or maintainedsubstantially at the set speed within thirty revolutions per minute(e.g., 10 RPM, 20 RPM, 30 RPM, etc.) of the set speed. The speed controltime depends upon how much the actual inducer motor speed deviated fromthe required or set speed. For example, if the deviation (speeddifference) is 10 RPM to 200 RPM, it may take 0.5 to 2 seconds tocontrollably regulate the actual inducer motor speed to the set speed.Or, for example, if the actual speed and required/set speed differs bymore than 500 RPM, it may take 2 to 3 seconds. By way of example, thecontrol may be configured such that it can take speed corrective actionevery 32 milliseconds.

In an exemplary embodiment, the method includes determining whether theset speed is less than a maximum speed of the inducer motor. If it isdetermined that the set speed is less than the maximum speed of theinducer motor, then the method includes regulating the actual inducermotor speed.

Regulating the actual inductor motor speed includes determining whethera predetermined amount of time has expired. If it is determined that thepredetermined amount of time has not expired, then the method includeswaiting. If it is determined that the predetermined amount of time hasexpired, then the method includes determining the actual inducer motorspeed (e.g., by using a hall effect sensor or other speed sensor, etc.).

After determining the actual inducer motor speed, the method includesdetermining whether the actual inducer motor speed is greater than a sumof the set speed plus a first delta speed. If it is determined that theactual inducer motor speed is greater than the sum of the set speed plusthe first delta speed, then the method includes reducing the actualinducer motor speed by using a switching device (e.g., a triac, atransistor, a silicon controlled rectifier or semiconductor controlledrectifier (SCR), other switching device, etc.) with a higher (e.g.,highest) firing angle to thereby obtain a lowest stator voltage for theinducer motor.

If it is determined that the actual inducer motor speed is not greaterthan the sum of the set speed plus the first delta speed, then themethod includes determining whether the actual inducer motor speed isless than a difference of the set speed minus a third delta speed.

If it is determined that the actual inducer motor speed is less than thedifference of the set speed minus the third delta speed, then the methodincludes increasing the actual inducer motor speed by using theswitching device with a lower (e.g., lowest) firing angle to therebyobtain a highest stator voltage or the inducer motor. If it isdetermined that the actual inducer motor speed is not less than thedifference of the set speed minus the third delta speed, then the methodincludes determining whether the actual inducer motor speed is less thana difference of set speed minus a second delta speed.

If it is determined that the actual inducer motor speed is less than thedifference of set speed minus the second delta speed, then the methodincludes reducing the firing angle of the switching device by a firstoffset that is a first percentage value of a difference of the set speedminus the actual inducer motor speed, to thereby increase the actualinducer motor speed. If it is determined that the actual inducer motorspeed is not less than the difference of set speed minus the seconddelta speed, then the method includes determining whether the actualinducer motor speed is greater than a sum of the set speed plus thesecond delta speed.

If it is determined that the actual inducer motor speed is not greaterthan the sum of the set speed plus the second delta speed, then themethod includes maintaining or not changing the firing angle of theswitching device. If it is determined that the actual inducer motorspeed is greater than the sum of the set speed plus the second deltaspeed, then the method includes increasing the firing angle of theswitching device by a second offset that is a second percentage value ofa difference of the actual inducer motor speed minus the set speed, tothereby decrease the actual inducer motor speed.

In this exemplary method, the first delta speed is 20 revolutions perminute (RPM), the second delta speed is 10 RPM, and the third deltaspeed is 200 RPM. The second delta speed is the +/−delta RPM to the setspeed within which inducer motor speed is maintained. Also in thisexemplary method, the first and second percentage values may each be25%. In another exemplary method, the first delta speed may be set to anRPM value within a range from 30 RPM to 60 RPM, the second delta speedmay be set to an RPM value within a range from 10 RPM to 30 RPM, thethird delta speed may be set to an RPM value within a range from 100 RPMto 400 RPM, and the first and second percentage values may each behigher or lower than 25%.

In exemplary embodiments, the method may include maintaining the actualinducer motor speed constant substantially at the set speed (e.g.,within 10 RPM, etc.) if line voltage changes to the inducer motor. Theinducer motor may comprise a single phase motor configured for useand/or being used as a furnace inducer. Exemplary embodiments include asystem configured for controlling inducer motor speed according to themethod(s) disclosed herein. For example, an exemplary system may includea triac configured to be operable for changing stator voltage of theinducer motor by changing the firing angle of the triac; a hall effectsensor configured to be operable for determining the actual inducermotor speed; and a control configured to be operable for changing thefiring angle of the triac to the value at which the actual inducer motorspeed is controllably regulated and/or maintained substantially at theset speed substantially without any speed oscillations.

In an exemplary embodiment, a system for controlling inducer motor speedincludes a switching device, a speed sensor, and a control. Theswitching device is configured to be operable for changing statorvoltage of an inducer motor. The speed sensor is configured to beoperable for determining actual inducer motor speed. The control isconfigured to be operable for changing the stator voltage of the inducermotor to a value at which the actual inducer motor speed is controllablyregulated and/or maintained substantially at a set speed substantiallywithout any speed oscillations.

The switching device may comprise a triac configured to be operable forchanging the stator voltage of the inducer motor by changing a firingangle of the triac. The control may be configured to be operable forchanging the firing angle of the triac to a triac firing angle value atwhich the actual inducer motor speed is controllably regulated and/ormaintained substantially at a set speed substantially without any speedoscillations. Other exemplary embodiments may include other switchingdevices for controlling motor stator voltage such as transistors,silicon controlled rectifiers or semiconductor controlled rectifiers(SCR), etc.

The speed sensor may comprise a hall effect sensor configured to beoperable for determining actual inducer motor speed. But other exemplaryembodiments may include other speed sensors or devices for determiningactual inducer motor speed.

In exemplary embodiments, the control comprises aproportional-integral-derivative (PID), proportional-integral (PI),and/or a proportional-derivative (PD) controller that is configured tobe operable for changing the stator voltage of the inducer motor to thevalue at which the actual inducer motor speed is controllably regulatedand/or maintained substantially at the set speed substantially withoutany speed oscillations by using the proportional-integral-derivative(PID), proportional-integral (PI), and/or a proportional-derivative (PD)process.

The system may be configured to be operable for controllably regulatingand/or maintained the actual inducer motor speed within 30 RPM (e.g., 10RPM, 20 RPM, 30 RPM, etc.) of the set speed without speed oscillations.A modulating furnace may include a furnace inducer and the system thatis configured for controlling speed of the furnace inducer.

In exemplary embodiments, a method includes changing the stator voltageof the inducer motor to a value at which the actual inducer motor speedis controllably regulated and/or maintained substantially at the setspeed substantially without any speed oscillations by using aproportional-integral-derivative (PID), proportional-integral (PI),and/or a proportional-derivative (PD) process or controller.

Exemplary embodiments of the systems and methods disclosed herein mayinclude or provide one or more (but not necessarily any or all) of thefollowing advantages or features, such as:

-   Enable replacement of conventional variable frequency drive (VFD)    mechanisms with lower cost triac circuitry for modulating furnaces    as disclosed exemplary embodiments may be used to precisely regulate    inducer motor speed at a set/desired speed;-   Usable in Low NOX controls;-   Maintain inducer motor speed at set speed in a short time (e.g.,    less than a few seconds, etc.) substantially without any    oscillations (e.g., without any significant oscillations, without    any oscillations, etc.);-   Maintain constant inducer motor speed if line voltage changes; and-   Faster response time to a newly requested inducer motor speed.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms, and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail. In addition, advantages and improvements that maybe achieved with one or more exemplary embodiments of the presentdisclosure are provided for purpose of illustration only and do notlimit the scope of the present disclosure, as exemplary embodimentsdisclosed herein may provide all or none of the above mentionedadvantages and improvements and still fall within the scope of thepresent disclosure.

Specific dimensions, specific materials, and/or specific shapesdisclosed herein are example in nature and do not limit the scope of thepresent disclosure. The disclosure herein of particular values andparticular ranges of values for given parameters are not exclusive ofother values and ranges of values that may be useful in one or more ofthe examples disclosed herein. Moreover, it is envisioned that any twoparticular values for a specific parameter stated herein may define theendpoints of a range of values that may be suitable for the givenparameter (i.e., the disclosure of a first value and a second value fora given parameter can be interpreted as disclosing that any valuebetween the first and second values could also be employed for the givenparameter). For example, if Parameter X is exemplified herein to havevalue A and also exemplified to have value Z, it is envisioned thatparameter X may have a range of values from about A to about Z.Similarly, it is envisioned that disclosure of two or more ranges ofvalues for a parameter (whether such ranges are nested, overlapping ordistinct) subsume all possible combination of ranges for the value thatmight be claimed using endpoints of the disclosed ranges. For example,if parameter X is exemplified herein to have values in the range of1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may haveother ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3,3-10, and 3-9.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. Forexample, when permissive phrases, such as “may comprise”, “may include”,and the like, are used herein, at least one embodiment comprises orincludes the feature(s). As used herein, the singular forms “a”, “an”and “the” may be intended to include the plural forms as well, unlessthe context clearly indicates otherwise. The terms “comprises,”“comprising,” “including,” and “having,” are inclusive and thereforespecify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof. The method steps,processes, and operations described herein are not to be construed asnecessarily requiring their performance in the particular orderdiscussed or illustrated, unless specifically identified as an order ofperformance. It is also to be understood that additional or alternativesteps may be employed.

When an element or layer is referred to as being “on”, “engaged to”,“connected to” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto”, “directly connected to” or “directly coupled to” another element orlayer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

The term “about” when applied to values indicates that the calculationor the measurement allows some slight imprecision in the value (withsome approach to exactness in the value; approximately or reasonablyclose to the value; nearly). If, for some reason, the imprecisionprovided by “about” is not otherwise understood in the art with thisordinary meaning, then “about” as used herein indicates at leastvariations that may arise from ordinary methods of measuring or usingsuch parameters. For example, the terms “generally”, “about”, and“substantially” may be used herein to mean within manufacturingtolerances.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”,“lower”, “above”, “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements, intended orstated uses, or features of a particular embodiment are generally notlimited to that particular embodiment, but, where applicable, areinterchangeable and can be used in a selected embodiment, even if notspecifically shown or described. The same may also be varied in manyways. Such variations are not to be regarded as a departure from thedisclosure, and all such modifications are intended to be includedwithin the scope of the disclosure.

1. A method of controlling inducer motor speed, the method comprising:changing stator voltage of an inducer motor; determining actual inducermotor speed; and after determining the actual inducer motor speed,changing the stator voltage of the inducer motor to a value at which theactual inducer motor speed is controllably regulated and/or maintainedsubstantially at a set speed without substantial speed oscillations. 2.The method of claim 1, wherein after determining the actual inducermotor speed, the method includes: determining whether the actual inducermotor speed is greater than a sum of the set speed plus a first deltaspeed; and if it is determined that the actual inducer motor speed isgreater than the sum of the set speed plus the first delta speed, thenthe method includes reducing the actual inducer motor speed by using aswitching device with a higher firing angle to thereby obtain a lowerstator voltage for the inducer motor.
 3. The method of claim 2, whereinreducing the actual inducer motor speed by using a switching device witha higher firing angle to thereby obtain a lower stator voltage for theinducer motor comprises reducing the actual inducer motor speed by usinga switching device with a highest firing angle to thereby obtain alowest stator voltage for the inducer motor.
 4. The method of claim 2,wherein if it is determined that the actual inducer motor speed is notgreater than the sum of the set speed plus the first delta speed, thenthe method includes determining whether the actual inducer motor speedis less than a difference of the set speed minus a third delta speed. 5.The method of claim 4, wherein if it is determined that the actualinducer motor speed is less than the difference of the set speed minusthe third delta speed, then the method includes increasing the actualinducer motor speed by using the switching device with a lower firingangle to thereby obtain a higher stator voltage for the inducer motor.6. The method of claim 5, wherein increasing the actual inducer motorspeed by using the switching device with a lower firing angle to therebyobtain a higher stator voltage for the inducer motor comprisesincreasing the actual inducer motor speed by using the switching devicewith a lowest firing angle to thereby obtain a highest stator voltagefor the inducer motor.
 7. The method of claim 5, wherein if it isdetermined that the actual inducer motor speed is not less than thedifference of the set speed minus the third delta speed, then the methodincludes determining whether the actual inducer motor speed is less thana difference of set speed minus a second delta speed.
 8. The method ofclaim 7, wherein: if it is determined that the actual inducer motorspeed is less than the difference of set speed minus the second deltaspeed, then the method includes reducing the firing angle of theswitching device by a first offset that is a first percentage value of adifference of the set speed minus the actual inducer motor speed, tothereby increase the actual inducer motor speed; or if it is determinedthat the actual inducer motor speed is not less than the difference ofset speed minus the second delta speed, then the method includesdetermining whether the actual inducer motor speed is greater than a sumof the set speed plus the second delta speed.
 9. The method of claim 8,wherein: if it is determined that the actual inducer motor speed is notgreater than the sum of the set speed plus the second delta speed, thenthe method includes maintaining the firing angle of the switchingdevice; or if it is determined that the actual inducer motor speed isgreater than the sum of the set speed plus the second delta speed, thenthe method includes increasing the firing angle of the switching deviceby a second offset that is a second percentage value of a difference ofthe actual inducer motor speed minus the set speed, to thereby decreasethe actual inducer motor speed.
 10. The method of claim 9, wherein: thefirst delta speed is within a range from 30 revolutions per minute to 60revolutions per minute; the second delta speed is within a range from100 revolutions per minute to 30 revolutions per minute; and the thirddelta speed is within a range from 100 revolutions per minute to 400revolutions per minute.
 11. The method of claim 10, wherein: the firstpercentage value is 25%, and the second percentage value is 25%; and/orthe switching device comprises a triac configured to be operable forchanging the stator voltage of the inducer motor by changing a firingangle of the triac; and/or the first delta speed is 20 revolutions perminute, the second delta speed is 10 revolutions per minute; and thethird delta speed is 200 revolutions per minute.
 12. The method of claim1, wherein: changing stator voltage of the inducer motor compriseschanging a firing angle of a triac; and after determining the actualinducer motor speed, the method includes changing the firing angle ofthe triac to a triac firing angle value at which the actual inducermotor speed is controllably regulated and/or maintained substantially atthe set speed.
 13. The method of claim 1, wherein determining actualinducer motor speed comprises using a hall effect sensor.
 14. The methodof claim 1, wherein after determining the actual inducer motor speed,the method includes changing the stator voltage of the inducer motorsuch that the actual inducer motor speed is controllably regulatedand/or maintained at the set speed within less than 4 seconds andwithout significant speed oscillations.
 15. The method of claim 1,wherein after determining the actual inducer motor speed, the methodincludes changing the stator voltage of the inducer motor such that theactual inducer motor speed is controllably regulated and/or maintainedto be within thirty revolutions per minute or less of the set speed. 16.The method of claim 1, wherein the method includes: determining whetherthe set speed is less than a maximum speed of the inducer motor; andregulating the actual inducer motor speed if it is determined that theset speed is less than the maximum speed of the inducer motor.
 17. Themethod of claim 16, wherein regulating the actual inductor motor speedincludes determining whether a predetermined amount of time has expired;if it is determined that the predetermined amount of time has notexpired, then the method includes waiting; or if it is determined thatthe predetermined amount of time has expired, then the method includesdetermining the actual inducer motor speed.
 18. The method of claim 1,wherein the method includes maintaining the actual inducer motor speedconstant substantially at the set speed if line voltage changes to theinducer motor.
 19. The method of claim 1, wherein the inducer motorcomprises a single phase motor configured for use as a furnace inducer.20. The method of claim 1, wherein after determining the actual inducermotor speed, the method includes changing the stator voltage of theinducer motor to the value at which the actual inducer motor speed iscontrollably regulated and/or maintained substantially at the set speedwithout significant speed oscillations by using aproportional-integral-derivative (PID), proportional-integral (PI),and/or a proportional-derivative (PD) control method.
 21. A systemconfigured for controlling inducer motor speed according to the methodof claim
 1. 22. A system for controlling inducer motor speed, the systemcomprising: a switching device configured to be operable for changingstator voltage of an inducer motor; a speed sensor configured to beoperable for determining actual inducer motor speed; and a controlconfigured to be operable for changing the stator voltage of the inducermotor to a value at which the actual inducer motor speed is controllablyregulated and/or maintained substantially at a set speed withoutsignificant speed oscillations.
 23. The system of claim 22, wherein: thecontrol is operable for determining whether the actual inducer motorspeed is greater than a sum of the set speed plus a first delta speed;and if the control determines that the actual inducer motor speed isgreater than the sum of the set speed plus the first delta speed, thenthe control is operable for reducing the actual inducer motor speed byusing the switching device with a higher firing angle to thereby obtaina lower stator voltage for the inducer motor.
 24. The system of claim23, wherein the control is operable for reducing the actual inducermotor speed by using the switching device with a highest firing angle tothereby obtain a lowest stator voltage for the inducer motor.
 25. Thesystem of claim 23, wherein if the control determines that the actualinducer motor speed is not greater than the sum of the set speed plusthe first delta speed, then the control is operable for determiningwhether the actual inducer motor speed is less than a difference of theset speed minus a third delta speed.
 26. The system of claim 25, whereinif the control determines that the actual inducer motor speed is lessthan the difference of the set speed minus the third delta speed, thenthe control is operable for increasing the actual inducer motor speed byusing the switching device with a lower firing angle to thereby obtain ahigher stator voltage for the inducer motor.
 27. The system of claim 26,wherein the control is operable for increasing the actual inducer motorspeed by using the switching device with a lowest firing angle tothereby obtain a highest stator voltage for the inducer motor.
 28. Thesystem of claim 22, wherein the control comprises aproportional-integral-derivative (PID), proportional-integral (PI),and/or a proportional-derivative (PD) controller that is configured tobe operable for changing the stator voltage of the inducer motor to thevalue at which the actual inducer motor speed is controllably regulatedand/or maintained substantially at the set speed without significantspeed oscillations by using the proportional-integral-derivative (PID),proportional-integral (PI), and/or a proportional-derivative (PD)control method.
 29. The system of claim 22, wherein: the switchingdevice comprises a triac configured to be operable for changing thestator voltage of the inducer motor by changing a firing angle of thetriac; the speed sensor comprises a hall effect sensor configured to beoperable for determining actual inducer motor speed; and the control isconfigured to be operable for changing the firing angle of the triac toa triac firing angle value at which the actual inducer motor speed iscontrollably regulated and/or maintained substantially at a set speedwithout significant speed oscillations.
 30. The system of claim 22,wherein the system is configured to be operable for controllablyregulating and/or maintaining the actual inducer motor speed to bewithin thirty revolutions per minute of the set speed withoutsignificant speed oscillations.
 31. A modulating furnace comprising afurnace inducer and the system of claim 22 configured for controllingspeed of the furnace inducer.